Abstract
The application of direct metal laser sintering renders it possible to manufacture models with complex geometries. However, there are certain limits to the application of this method connected with manufacturing thin-walled cuboidal elements, as well as cylinders and holes with small diameters. The principal objective of the research was to determine the accuracy of manufacturing geometries with small cross-sections and the possibility of application in heat exchangers that are radiators with radially arranged ribs. To that end, four specimens were designed and manufactured; their geometries of representations assumed for the purpose of research (analysis) changed dimensions within the following scope: 10–0.1 mm. The specimens to be applied in the research were manufactured with 17-4 PH stainless steel (1.4542) with the application of 3D-DMLS printing and an EOS M270 printer. The measurement of accuracy was performed with the application of an optical stereomicroscope (KERN OZL-466). In addition to that, research into the chemical composition of the material, as well as the size of spherical agglomerates, was conducted with the application of a scanning electron microscope. The analysis of the chemical composition was conducted as well (after the sintering process). The analysis of the results based on the values received by means of measurements of the manufactured geometries was divided into three parts. Based on this, it is possible to conclude that the representation of models manufactured with the application of DMLS was comparable with the assumptions, and that the deviations between a nominal dimension and that received in the course of the research were within the following scope: 0–0.1 mm. At the final stage of research and based on the received results, two heat exchangers were manufactured.
Highlights
Throughout recent years, it has been possible to observe a significant development in rapid prototyping methods, which is contributed to by an ever-greater interest of numerous industries such as the aviation industry [1–10]
DMLS is an alternative to models manufactured with the application of casting processes
Already at the modeling stage of a complex structure, the constructor must have basic knowledge related to the specifics of the DMLS process
Summary
Throughout recent years, it has been possible to observe a significant development in rapid prototyping methods, which is contributed to by an ever-greater interest of numerous industries such as the aviation industry [1–10]. An additional advantage is that it renders it possible to avoid so-called indirect modeling, and, to reduce the inaccuracy of dimensions. This method renders it possible to manufacture models with a complex geometry, frequently impossible to manufacture with the application of conventional manufacturing methods [13,14]. Limits to the application of this method connected with manufacturing thin-walled cuboidal elements, and cylinders and holes with a small diameter, ought to be taken under consideration. It is a very important aspect to manufacture such geometries with appropriate accuracy, and to ensure allowances for further post-processing [15,16]
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